Artificial firelog and firestarter chip producing apparatus and method and products produced therefrom

ABSTRACT

An artificial firelog and firestarter chip producing apparatus comprising a cutting assembly, a compression conveyor auger assembly and a die. The apparatus converts standard waxed corrugated cardboard boxes into artificial firelogs by first slicing cardboard sheets into cardboard strips, then chopping the cardboard strips into cardboard segments in the cutting assembly. The cardboard segments are horizontally disposed between the rifling and compressed in the compression conveyor auger assembly and extruded in the die to form generally horizontally disposed, circular, longitudinally-shaped sections of a firelog. Firestarter chips are fabricated by the cutting assembly, which slices waxed cardboard sheets in conjunction with paper sheets into waxed cardboard and paper strips, then chopping the waxed cardboard strips into waxed cardboard segments and the paper strips into paper segments and waxed cardboard segments mix.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application is a continuation of U.S. application Ser. No.09/754,240 filed on Jan. 3, 2001, now U.S. Pat. No. ______, which is adivisional of U.S. application Ser. No. 09/409,647 filed on Oct. 1,1999, now U.S. Pat. No. 6,655,943, incorporated herein by reference,which in turn is (i) a continuation-in-part of U.S. application Ser. No.09/165,270 filed on Oct. 1, 1998, now U.S. Pat. No. 6,251,147,incorporated herein by reference, and (ii) a 35 U.S.C. § 111(a)continuation of international application serial number PCT/US99/23007filed on Sep. 30, 1999. Priority is claimed to each of the foregoingapplications.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

[0002] Not Applicable

INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC

[0003] Not Applicable

NOTICE OF MATERIAL SUBJECT TO COPYRIGHT PROTECTION

[0004] A portion of the material in this patent document is subject tocopyright protection under the copyright laws of the United States andof other countries. The owner of the copyright rights has no objectionto the facsimile reproduction by anyone of the patent document or thepatent disclosure, as it appears in the United States Patent andTrademark Office publicly available file or records, but otherwisereserves all copyright rights whatsoever. The copyright owner does nothereby waive any of its rights to have this patent document maintainedin secrecy, including without limitation its rights pursuant to 37C.F.R. § 1.14.

BACKGROUND OF THE INVENTION

[0005] 1. Field of the Invention

[0006] The present invention pertains generally to a fuel manufacturingapparatus, and more particularly to an apparatus and method forconverting flammable material, such as waxed corrugated cardboard, intocompact artificial firelogs or firestarter chips.

[0007] 2. Description of the Background Art

[0008] The popularity of log burning fireplaces as an amenity and as asupplemental source of heat continues to grow. With cutting restrictionson Government land, as well as the closing of many wood processingplants, wood logs can be difficult and expensive to obtain. As a result,artificial firelogs, which generally burn cleaner and light faster, havebeen gaining in popularity.

[0009] On the other hand, boxes and containers made from cardboard arewidely used in an almost infinite variety of applications such aspackaging produce, shipping and storage of goods and the like. As such,there is an abundant supply of discarded cardboard boxes readilyavailable for recycling. It has been recognized that discarded cardboardboxes form a potential fuel material, and the general concept ofconverting used or discarded cardboard boxes into burnable firelogs hasbeen applied with some level of success.

[0010] Machines have been previously developed to convert such cardboardboxes into compact burnable firelogs. Such machines include a feedsystem, such as a hammermill for receiving a sheet of cardboard, acutting mechanism for slicing the cardboard sheet into strips and thencutting the strips into chips, and a compacting/compressing punch pressassembly for shaping the chips into compact firelog structures which canbe burned in a fireplace. Binders, such as glue, are used to hold thechips together after compression. Additionally, the finished firelogscan be dipped into wax to create an outer wax coating to enhance theirburn capability.

[0011] These existing machines, however, are designed to cut and shapeplain cardboard boxes; that is, cardboard without a wax or wax-likecoating thereon. Existing machines are not made to cut and shape waxedcorrugated cardboard. Furthermore, the design of these machines does nottake into account that, by using glue as a binder to hold regularunwaxed cardboard together into a compressed log, the corrugations aredestroyed when the strips or chips are smashed and glued together. Quitesignificantly, we have found that regular and waxed corrugated cardboardhas a memory and, while the corrugated segments stick together they areflattened and compressed, if glue is not used as a binder, upon heatingthe corrugated segments expand back into an open structure through whichairflow is increased which leads to more efficient burning. Current firelog production machines are not able to make use of this memory propertyof corrugated cardboard.

[0012] It will be appreciated that resource conservation continues to beimportant as our population increases and our level of resourcesdiminish. Therefore corrugated cardboard boxes, as is the case with manyother materials, are generally recycled to reduce waste. Wax-coatedcorrugated cardboard boxes, however, are generally non-recyclable.Wax-coated corrugated cardboard boxes are commonly coated with aparaffin-based wax which is very expensive to separate from thecardboard within a normal re-pulping systems. Consequently, usedwax-coated corrugated cardboard boxes (WOCC) are generally discarded inlandfills. In view of present interests regarding conservation ofresources and environmental consciousness, the ability to reuse suchdiscarded material in a form of fuel would serve to reduce the demandfor other types of fuels, such as oil, gas or coal, thus furtherconserving natural resources and preserving the environment.

[0013] Additionally, current log manufacturing machines destroy thecorrugation within the corrugated cardboard which reduces the flow andpermeation of wax and oxygen throughout the firelog which results in anincomplete and inefficient burning of the firelog.

[0014] Moreover, current log manufacturing machines produce firelogswith “cold joints” at the intervals between punches or presses. Thesecold joints are also formed when the chips are compressed verticallywithin the structure of the log rather than disposed horizontally aroundthe log in a circular fashion. Cold joints are weak links within thefirelog that easily break up into multiple sections when any shear ortensile force is exerted upon them. The punch or press machine createsvertical arrangements of the chips within the firelog. When burned, thevertical chip arrangement causes chips to burn from the edge rather thanfrom the side. Therefore chips of corrugated cardboard, so pressed intoa log, are not allowed to open and expand with heat because of thevertical arrangement and the glued corrugations.

[0015] Accordingly, there exists a need for an artificial firelogmanufacturing apparatus that provides the capability to recyclepre-waxed corrugated cardboard boxes into firelogs that are morestructurally rigid and that burn more efficiently, using horizontallydisposed segments, over that which is presently known in the art. Thepresent invention satisfies those needs, as well as others, andovercomes the deficiencies found in currently known artificial firelogproducing machines.

BRIEF SUMMARY OF THE INVENTION

[0016] The present invention is an apparatus which converts standard waxcoated corrugated cardboard sheets into artificial firelogs, orfirestarter chips. The apparatus can therefore create firelogs from thewax-coated corrugated material that would otherwise be disposed ofwithin landfills. Recycling this wax-coated material by means of thisapparatus can create the equivalent of 600 million, 5-pound firelogsannually.

[0017] The invention produces artificial firelogs or firestarter chips,by first slicing waxed corrugated cardboard sheets into strips, and thencutting the strips into segments. Each cut segment retains its originalcorrugated structure and wax content. The wax-coated corrugatedcardboard segments are then compressed and shaped longitudinally intofirelogs which are generally cylindrical. The longitudinal orientationof the segments, whose corrugated structure has been retained, coupledwith the memory effect exhibited by the compressed corrugated cardboard,results in a more efficient burn as the segments open up to increaseairflow. Furthermore, by adding wax, or wax-like materials, any form ofnew, remnant, or recycled unwaxed corrugated cardboard can be processedinto artificial firelogs and firestarters.

[0018] By way of example and not of limitation, the artificial firelogproducing apparatus of the present invention generally comprises acardboard strip cutting mechanism, a segment cutting mechanism, and aconveyor compression mechanism. The strip cutting mechanism employs aplurality of upper circular blades with teeth juxtaposed axially, and aplurality of lower circular blades with teeth juxtaposed axially suchthat the cutting edge of the upper circular blades overlap the cuttingedge of the lower circular blades whose interaction cuts the waxedcorrugated cardboard sheets into waxed corrugated cardboard strips. Asegment cutting mechanism in the form of a cutting reel is disposedadjacent to the lower circular blade which then cuts the strips of waxedcorrugated cardboard into segments. A conveyor compression mechanism inthe form of an auger is positioned beneath the cutting reel andterminates in a log forming die for conveying and compressing thecorrugated segments into a log shaped extrusion.

[0019] The upper and lower circular blades in the strip cuttingmechanism effectively meter and slice multiple waxed corrugatedcardboard sheets fed therein into waxed corrugated cardboard strips. Thewaxed corrugated cardboard strips are then fed through the cutting reelwhich cuts the waxed corrugated cardboard strips into waxed corrugatedcardboard segments. The waxed corrugated cardboard segments are then fedinto the conveyor compression auger for transport and compression into alog die. As the conveyor compression auger transports the waxedcorrugated cardboard segments, the segments are horizontally disposedaround the housing between rifling in a circular interlocking manner andare gradually compressed and forced into the log die. The log diecompresses and shapes the waxed corrugated cardboard segments intoartificial firelogs. Alternately the exit portion of the housing may beconfigured to perform the functions of the log die; however thisprecludes changing log forms without major changes to the apparatus.Firestarter chips are produced by bypassing the auger and log die.

[0020] Use of a conveyor compression auger results is a significantimprovement over punch press-type machines, because the conveyorcompression auger horizontally (based on the longitudinal axis of thefirelog) flattens the waxed corrugated cardboard segments, as opposed tovertically flattening or crushing the cardboard segments which, as aresult, form cold joints in logs produced from these piston stylesystems. The conveyor compression auger with its internal rifling alsoeliminates cold joints in the firelog by spinning the flattened chipshorizontally and interlocking them throughout the log, thus eliminatingthe likelihood of the firelog breaking into segments on the fireplacegrate. The horizontal (longitudinal) orientation also allows thesegments to expand and burn off the exterior of the log, layer afterflattened layer. As each flattened corrugated segment is being consumedby the flames, it expands from the memory effect in the corrugationswhich thereby allows the air to flow through the segment for a moreefficient burn. Once a segment has been consumed, it falls away as thenext layered segment starts burning. This burning sequence continuesuntil the entire log has been consumed. Therefore the inventiveapparatus retains the corrugation structure and creates a longitudinalsegment orientation to provide for the manufacture of firelogs which donot easily break and which burn in a similar manner to genuine woodbark.

[0021] An object of the invention is to provide an apparatus capable ofprocessing pre-waxed corrugated cardboard to produce artificialfirelogs.

[0022] Another object of the invention is to provide an apparatuscapable of producing artificial firelogs more efficiently than firelogproducing machines presently known or available.

[0023] Another object of the invention is to provide an apparatuscapable of reliably feeding, slicing and cutting waxed corrugatedcardboard sheets and paper sheets into waxed corrugated cardboardsegments and paper segments mix.

[0024] Another object of the invention is to provide an apparatuscapable of reliably slicing and cutting waxed corrugated cardboardsheets and waxed corrugated cardboard segments without the need ofremoving the wax or with the result of destroying the corrugationswithin.

[0025] Another object of the invention is to provide an apparatuscapable of producing artificial firelogs without the necessity of addingglue or wax.

[0026] Another object of the invention is to provide an apparatus thatproduces firelogs without cold joints.

[0027] Another object of the invention is to provide an apparatus thatproduces a firelog with horizontally interlocking arranged segments.

[0028] Another object of the invention is to provide an apparatuswherein waxed corrugated cardboard segments are transported andcompressed into an artificial firelog in which the segments are spunhorizontally and disposed radially in an interlocking manner around theoutside of the firelog, so that each sequential flattened layer ofsegments expands open when burning.

[0029] Another object of the invention is to provide an apparatus whichis capable of producing firestarter chips.

[0030] Another object of the invention is to provide an apparatus whichis capable of producing firestarter blends containing a variety ofdifferent materials.

[0031] Another object of the invention is to provide an apparatuscapable of producing a log having a outer covering which can be used asa post.

[0032] Further objects and advantages of the invention will be broughtout in the following portions of the specification, wherein the detaileddescription is for the purpose of fully disclosing preferred embodimentsof the invention without placing limitations thereon.

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The invention will be more fully understood by reference to thefollowing drawings which are for illustrative purposes only:

[0034]FIG. 1 is a front sectional view of an artificial firelogproducing apparatus of the present invention shown with guide platesremoved.

[0035]FIG. 2 is a front sectional view of the artificial firelogproducing apparatus of FIG. 1 shown with guide plates installed.

[0036]FIG. 3 is a rear view of the artificial firelog producingapparatus shown in FIG. 1.

[0037]FIG. 4 is a front sectional partial view of the conveyorcompression auger assembly and firelog die portions of the presentinvention shown with an extruded firelog.

[0038]FIG. 5 is a detailed front sectional view of the conveyorcompression auger assembly and firelog die shown in FIG. 4.

[0039]FIG. 6 is a detailed front sectional view of the conveyorcompression auger assembly and firelog die of FIG. 5 showing the forwardpitch of the helical blade of the conveyor compression auger assembly ofthe present invention.

[0040]FIG. 7 is a front view of the conveyor compression auger of thepresent invention shown from left to right.

[0041]FIG. 8 is a half conical schematic of the conveyor compressionauger of FIG. 7 shown from right to left.

[0042]FIG. 9 is a schematic side view of the conveyor compression augerof FIG. 7 showing flights and stations along the helical auger blade asseen from right to left.

[0043]FIG. 10 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the forward pitch and weldfill of the blade cross for the 1^(st) 15 degree sweep (0-15 degrees).

[0044]FIG. 11 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 2^(nd) 15 degree sweep(15-30 degrees).

[0045]FIG. 12 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 3^(rd) 15 degree sweep(30-45 degrees).

[0046]FIG. 13 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 4^(th) 15 degree sweep(45-60 degrees).

[0047]FIG. 14 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 5^(th) 15 degree sweep(60-75 degrees).

[0048]FIG. 15 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 6^(th) 15 degree sweep(75-90 degrees).

[0049]FIG. 16 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 7^(th) 15 degree sweep(90-105 degrees).

[0050]FIG. 17 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 8^(th) 15 degree sweep(105-120 degrees).

[0051]FIG. 18 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 9^(th) 15 degree sweep(120-135 degrees).

[0052]FIG. 19 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 10^(th) 15 degree sweep(135-150 degrees).

[0053]FIG. 20 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 11^(th) 15 degree sweep(150-165 degrees).

[0054]FIG. 21 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 12^(th) through 24^(th)15 degree sweep (180-360 degrees).

[0055]FIG. 22 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 25^(th) through 48^(th)15 degree sweep of the second flight (0-360 degrees).

[0056]FIG. 23 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 49^(th) through 63^(rd)15 degree sweep of the third flight (0-225 degrees).

[0057]FIG. 24 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 64^(th) through 73^(rd)15 degree sweep of the third flight (225-0 degrees) and the first 15degree sweep of the fourth flight (0-15 degrees).

[0058]FIG. 25 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 74^(th) through 97^(th)15 degree sweep of the fourth flight (30-360 degrees) and the first(0-15 degrees) of the fifth flight.

[0059]FIG. 26 is a schematic side view of the conveyor compression augerof FIG. 7 as seen from left to right showing the 98^(th) through107^(th) 15 degree sweep of the fifth flight (30-150).

[0060]FIG. 27 is a pictorial side view of the 0-15 degree cross sectionof the unwelded tip of the conveyor compression auger assembly of thepresent invention.

[0061]FIG. 28 is a pictorial side view of the 0-15 degree cross sectionof the no front weld push tip of the conveyor compression auger assemblyof the present invention.

[0062]FIG. 29 is a pictorial side view of the 0-15 degree cross sectionof the fully welded tip and push section of the conveyor compressionauger assembly of the present invention.

[0063]FIG. 30 is a pictorial side view of the 15-30 degree cross sectionof the unwelded tip of the conveyor compression auger assembly of thepresent invention.

[0064]FIG. 31 is a pictorial side view of the 15-30 degree cross sectionof the no front weld push tip of the conveyor compression auger assemblyof the present invention.

[0065]FIG. 32 is a pictorial side view of the 15-30 degree cross sectionof the fully welded tip and push section of the conveyor compressionauger assembly of the present invention.

[0066]FIG. 33 is a pictorial side view of the 30-45 degree cross sectionof the unwelded tip of the conveyor compression auger assembly of thepresent invention.

[0067]FIG. 34 is a pictorial side view of the 30-45 degree cross sectionof the no weld push tip of the conveyor compression auger assembly ofthe present invention.

[0068]FIG. 35 is a pictorial side view of the 30-45 degree cross sectionof the fully welded tip and push section of the conveyor compressionauger assembly of the present invention.

[0069]FIG. 36 is a pictorial side view of the 45-60 degree cross sectionof the unwelded tip of the conveyor compression auger assembly of thepresent invention.

[0070]FIG. 37 is a pictorial side view of the 45-60 degree cross sectionof the no front weld push tip of the conveyor compression auger assemblyof the present invention.

[0071]FIG. 38 is a pictorial side view of the 45-60 degree cross sectionof the fully welded tip and push section of the conveyor compressionauger assembly of the present invention.

[0072]FIG. 39 is a pictorial side view of the 60-75 degree cross sectionof the unwelded tip of the conveyor compression auger assembly of thepresent invention.

[0073]FIG. 40 is a pictorial side view of the 60-75 degree cross sectionof the no front weld push tip of the conveyor compression auger assemblyof the present invention.

[0074]FIG. 41 is a pictorial side view of the 60-75 degree cross sectionof the fully welded tip of the conveyor compression auger assembly ofthe present invention.

[0075]FIG. 42 is a pictorial side view of the 75-90 degree cross sectionof the unwelded tip of the conveyor compression auger assembly of thepresent invention.

[0076]FIG. 43 is a pictorial side view of the 75-90 degree cross sectionof the no front weld push tip of the conveyor compression auger assemblyof the present invention.

[0077]FIG. 44 is a pictorial side view of the 75-90 degree cross sectionof the fully welded tip and push section of the conveyor compressionauger assembly of the present invention.

[0078]FIG. 45 is a pictorial opposing side view of the 15-30 degreecross section of FIG. 32.

[0079]FIG. 46 is a side view of the conical housing portion of theconveyor compression auger assembly of the present invention.

[0080]FIG. 47 is an end view of the conical housing shown in FIG. 46seen from the attachment point with the enclosure.

[0081]FIG. 48 is a side view of the log die and cooling jacket of thepresent invention.

[0082]FIG. 49 is an end view of the cooling jacket of FIG. 48 shown fromthe attachment point with the conical housing shown in FIG. 46.

[0083]FIG. 50 is a cross-sectional schematic of the auger housingshowing the cut cardboard segments during extrusion of a firelog(helical blade not shown).

[0084]FIG. 51 is a cross section view of the interior space within aterminal portion of the log die shown with representative waxedcorrugated cardboard segments radially compressed.

[0085]FIG. 52 is a side elevation view of the conical housing shownattached to a 4-inch firelog die corresponding to that shown in FIG. 4but seen from right to left.

[0086]FIG. 53 is a side elevation view of the conical housing shownattached to a 3.5-inch firelog die.

[0087]FIG. 54 is end view of the firelog die shown in FIG. 52.

[0088]FIG. 55 is a side view of an alternative embodiment of a firelogdie according to the present invention.

[0089]FIG. 56 is an exploded end view of the firelog die embodiment ofFIG. 55.

[0090]FIG. 57 is a partial right side view of the invention showing thewaxed corrugated cardboard cutting assembly.

[0091]FIG. 58 is a side view of a blade used within the cutting reel ofthe invention.

[0092]FIG. 59 is a side view of the cutting reel of the inventionshowing the helical placement of the blades.

[0093]FIG. 60 is a partial front view of the assembly for cutting waxedcorrugated cardboard strips, showing the relationship between the upperand lower circular blades and the central portions of the upper andlower guide plates.

[0094]FIG. 61 is a side view of a cutting blade spacer according to theinvention.

[0095]FIG. 62 is a front view of the cutting blade spacer of FIG. 61.

[0096]FIG. 63 is a side view of the overlapping section of the upper andlower circular blades as shown in FIG. 60.

[0097]FIG. 64 is a top plan view of the lower guide plate shown in FIG.57.

[0098]FIG. 65 is a right side view of the cutting assemblies of theinvention shown with a waxed corrugated cardboard sheet and paper sheetbeing fed into the machine along with the waxed corrugated cardboardsegments and paper segments produced.

[0099]FIG. 66 is a side elevation view of a bed bar assembly of theinvention with the angle shown between the bed bar assembly and thecenter shaft of the reel of the present invention.

[0100]FIG. 67 is a left side view of the apparatus shown in FIG. 1.

[0101]FIG. 68 is a right side view of the apparatus shown in FIG. 1.

[0102]FIG. 69 is a perspective view of an artificial firelogmanufactured by the apparatus of FIG. 1, showing representativehorizontally disposed radially displaced interlocking segments andexterior log ridges.

[0103]FIG. 70 is a top plan view (magnified) of a waxed corrugatedcardboard segment as used within the apparatus to form the firelog shownin FIG. 69.

[0104]FIG. 71 is a cross sectional view of the waxed corrugatedcardboard segment taken along line 71-71 in FIG. 70.

[0105]FIG. 72 is a cross sectional view of the waxed corrugatedcardboard segment of FIG. 71 which has been compressed.

[0106]FIG. 73 is a cross sectional view of the waxed compressedcorrugated cardboard segment of FIG. 72 after re-expansion when heated.

[0107]FIG. 74 is a flowchart of the steps to fabricate the firelog shownin FIG. 69.

DETAILED DESCRIPTION OF THE INVENTION

[0108] Referring more specifically to the drawings, for illustrativepurposes the present invention is embodied in the apparatus and methodsgenerally shown and described in FIG. 1 through FIG. 74, wherein likereference numerals denote like parts. It will be appreciated that theapparatus may vary as to configuration and as to details of the partsand that the method may vary as to the steps and their sequence withoutdeparting from the basic concepts as disclosed herein.

[0109] Referring first to FIG. 1 through FIG. 3, an artificial firelogmanufacturing apparatus 10 of the present invention is generally shown.Apparatus 10 generally comprises a waxed corrugated cardboard sheetcutting assembly 12, an enclosure 14, a compression auger conveyorassembly 16, a hopper 18 and a firelog die 20. Waxed corrugatedcardboard sheet cutting assembly 12 is positioned on enclosure 14 abovehopper 18. Hopper 18 is disposed within enclosure 14 and includes anupper opening 22, a discharge chute 24, and an auger trough 46.Discharge chute 24 is positioned adjacent auger conveyor assembly 16 sothat materials exiting from discharge chute 24 will be fed into augerconveyor assembly 16 by means of auger trough 46.

[0110] Conveyor compression auger assembly 16 is a compression typewhich comprises an auger trough 46, an auger housing 26, a log die 20,and a conveyor compression screw 28. Auger trough 46 is a semi-circularsection formed on the bottom of hopper 18 which includes an inlet end 30and an outlet end 32. An opening 34 within the conveyor compressionauger assembly 16, is in material communication with hopper 18, in whichan adjacent inlet end 30 is disposed within auger trough 46. A bore orcircular passageway 64 is disposed longitudinally through auger trough46, auger housing 26, and log die 20.

[0111] Conveyor compression screw 28 has a first end 36 and a second end40 of a shaft 42, upon which is attached an annularly disposed helicalscrew 44. First end 36 of shaft 42 is driven by attached spur gear 56. Ashoulder 38 of the shaft 42 is adjacent inlet end 30 of auger trough 46.A second end 40 of shaft 42 on the conveyor compression screw 28terminates adjacent recompression zone 184 of log die 20. Shaft 42incorporates a helical screw 44, between inlet end 30 of auger trough 46and recompression zone 184 of log die 20.

[0112] Shaft 42 is approximately 69-inches long and extends throughenclosure 14, therethrough inlet end 30 of auger trough 46 at the bottomof hopper 18, and terminates within the log die 20. Shaft 42 isrotatably disposed within a first pilot bearing 54 and a second pilotbearing 52, the bearings in combination support the cantilevered sectionof shaft 42 as the conveyor compression screw 28 transports cardboardsegments 48 a therethrough. First pilot bearing 54 is located onenclosure 14, and second pilot bearing 52 is located on an openingwithin the support plate 50 adjacent the auger trough 46. Shaft 42typically has an approximate diameter of 2½ inches for the first 35inches of its length, which begins at a first end 36 and continuesthrough first pilot bearing 54 and second pilot bearings 54 to ashoulder 38 of the shaft 42. The shaft 42 at the shoulder 38 steps up toan approximate 3 inch diameter as the cantilevered section of helicalscrew 44 begins. Shaft 42, containing helical screw 44, remains aconstant diameter of 3 inches for 19 inches, and then tapers down in thefinal 15 inches to approximately a 1-inch diameter, terminating adjacentthe start of the recompression zone 184, within the log die 20. There isa 6-inch standard keyway (not shown) beginning at the first end 36 ofshaft 42 adjacent first pilot bearing 54. Located around shaft 42 andkeyway are a nut (not shown), lockwasher (not shown) and spur gear 56.

[0113] Helical screw 44 adjacent second end 40 of conveyor screw 28 andincludes 5 flights 58 a-58 e through to the shoulder 38 of the conveyorcompression screw 28. Measuring from crest-to-crest, flights 58 a-58 eare spaced apart, from second end 40 to shoulder 38 of conveyor screw28, with proportionately increasing lengths. Flight 58 a has a maximumdiameter of about 4-inches at second end 40 of conveyor compressionscrew 28 and increases to about 7½ inches in the first three flights 58a, 58 b, 58 c, and remains constant through flights 58 d to 58 f. Flight58 f is a partial flight of 4.5 inches.

[0114] Referring also to FIG. 4 through FIG. 7, auger housing 26comprises a conical section 62 with a circular bolt flange 66 thatattaches to the enclosure 14, and a square bolt flange 70, to which thesquare bolt flange 84 of the log die 20 is attached. At the point ofattachment with the enclosure 14, the conical section 62 of augerhousing 26 has an inner diameter of approximately 8-inches and an outerdiameter of approximately 8½ inches. Within the enclosure 14, startingat the support plate 50, a semi-circular section comprises an augertrough 46 which partially surrounds the helical screw 44 forapproximately 15-inches. The upper portion provides for opening 34 toaccess conveyor compression screw 28. Auger housing 26 has a conicalsection 62 with a 2-inch wide circular bolt flange 66 which isconfigured to attach to the enclosure 14. Conical section 62 begins withan approximate inner diameter of 8-inches at the enclosure 14 and tapersdown to an approximate inner diameter of just under 5½ inches at the logdie 20. The taper of conical section 62 is preferably betweenapproximately 5° and 7.5°. A log die 20 is attached to the narrow end ofthe auger housing 26. The log die 20 receives the terminal end of theconveyor compression screw 28 within a conical zone 182. Finalcompression of the waxed corrugated cardboard segments is accomplishedwithin the compression zone 184 of the log die 20, and a final shapingzone 186 determines the size and shape of the resultant artificialfirelog being extruded. A circular passageway 64 extends continuouslyfrom a partial enclosure by auger trough 46, through fully encircledregions within auger housing 26 and log die 20.

[0115] Circular passageway 64 incorporates longitudinal rifling 72 alongthe majority of its length, including the inner walls of the augertrough 46, the auger housing 26, and the conical zone 182 of the log die20. The rifling 72 comprises a rail of four ¼″×¼″ keyway materialpositioned at 60°, 120°, 240°and 300°, respectively, along the interiorwalls of circular passageway 64. Rifling 72 keeps waxed corrugatedcardboard segments 48 a moving forward while being disposed horizontallyas seen in FIG. 50, thereby controlling the friction and heat generatedbetween the interior of both the auger housing 26 and log die 20, andthe waxed corrugated cardboard segments 48 a. It should be noted thatvarious waxed corrugated cardboard segment “states” are considered inthe disclosure. A brief look at FIG. 71 through FIG. 73 shows that threestates are addressed: (1) uncompressed waxed corrugated cardboardsegments 48 a, (2) compressed waxed corrugated cardboard segments 48 b,and (3) partially uncompressed 48 c as a result of memorycharacteristics when the compressed segment is heated.

[0116] Bleed holes (not shown) can be incorporated near the input end ofthe conical section 62 of the auger housing 26 to provide a means forintroducing scented oils and colors or additional wax withanti-bacterial properties during operation of conveyor compression screw28.

[0117] As can be seen in FIG. 6, the flights of the helical blade areangled forward towards log die 20 at various angles to more effectivelypush materials therethrough. The angles a1-a5 are contained in Table 1where a=forward angle of blade (FIG. 6), f=flight length (FIG. 8),h=blade height (FIG. 8), r=distance from exterior of blade to augerhousing (FIG. 8), and s=distance between stations (FIG. 9).

[0118]FIG. 7 shows the conveyor compression screw 28 in isolation. Amachined shaft section of length e1 (35.00 inches) and a diameter e1(2.500 inches) is held at both ends by bearings which stabilize theremaining cantilevered section of the shaft containing the helical augerblade. A non-tapered section of the conveyor compression screw extendswithin the enclosure for a length e2 (19.00 inches) with a fixedexterior diameter d2 (3.0 inches). A tapered section of length e3 (15.00inches) with a diameter that tapers to a minimum of d4 (1.000 inches) atthe end of the conical zone within the log die 20.

[0119]FIG. 8 is a conveyor compression screw 28 cross-section diagramshowing dimensions marks for the five flights of its helical screw 44.The length of each flight is given by f1-f5 and the height of the bladesabove the shaft 42 is given by h1-h5 as provided in Table 1. It shouldbe noted that the auger diameter correspondingly begins to taper as itenters the tapered section of the auger housing 26; the start of thetaper being further broken down into sections a-d, for each of which aseparate blade height value is given in Table 1. Space between theconveyor compression screw 28 and the interior of the circularpassageway 64, is given by r which remains as a constant gap of(0.2500). The gap of r provides spacing for the rifling 72 within thecompression screw housing so that the segments can be interlocked ontheir way to complete formation within the log die 20. FIG. 9 is adiagram of the five flights which depicts stations along the length ofthe conveyor compression screw 28. The angular displacement of theconveyor compression screw changes by 15° between stations and thedistance between each station varies with flight. The distance betweenstations is given by s1-s5 within Table 1.

[0120] Representative blades are shown in FIG. 10 through FIG. 26 withnoted dimensions given within Table 2 where St No.=Station Number,Flt=flight number(s), Degree=degrees covered within flight,s=station-to-station distance, b=blade height, p=length of pusher sideweld buildup, w=length of rear-side weld buildup, y=height of pusherweld buildup, t=height of rear-side weld buildup, g=forward tilt ofblade. Measurements are provided individually for the stations along thefirst half-flight, as a number of dimensions vary, whereas the remainingstation data is given for ranges of stations (12 to 24, 24 to 48, etc.).It can be seen from the progression of these figures the manner in whichthe blade height increases, the amount of tilt decreases, and thepusher-side and rear-side weld buildups get less pronounced on sectionsof the blade further away from the exit point of the log extrusion. Itmust be remembered that these measurements, being provided for thepreferred embodiment, in no way limit the practice of the invention;numerous obvious dimensional and structural changes may be introducedwithout inventive effort or departure from the underlying principlesthereof.

[0121] Representative blades of the first 90 degrees of the conveyorcompression screw are shown pictorially in FIG. 27 through FIG. 45 atvarious stations. Each section shows the helical screw 44 attached tothe shaft 42 of the conveyor compression screw 44 in an unwelded state,without a pusher-side weld buildup 154, and then with both a pusher-sidefront weld buildup 154 and a rear-side weld buildup 156. The chosenfillet material used within this embodiment is a buildup of weldmaterial, however any conventional fillet material may be used. Theangles β₁, β₂, β₃, as shown in the figures, are given in Table 3. FIG.45 shows the important first 15 degree section of the screw from theopposite direction wherein the exit face of the blade can be seen.

[0122]FIG. 46 and FIG. 47 show a side and end view of the auger housing26 as shown in FIG. 1. A conical section 62 of the auger housingprovides a taper matching that of the conveyor compression screw (notshown). The auger housing 26 is attached to the enclosure (not shown) bymeans of a circular bolt flange 66. A log die (not shown) is attached bymeans of a square bolt flange 84, preferably of a ½″×10″×10″configuration to the auger housing 26. Rifling 72 is shown within theinterior of the conical section 62 of the auger housing 26.

[0123]FIG. 48 and FIG. 49 show a side and an end view of the log die 20as shown in FIG. 1. The log die 20 comprises a housing 74, approximately18 inches in length, containing both an inlet side 76 and a materialoutlet side 78. The log die is attached to the conical auger housing viasquare bolt flange 84 wherein the inner opening 80 of the log diereceives the waxed compressed cardboard material pushed by the conveyorcompression screw (not shown). Three sections, or zones, exist along thelength of the log die: a conical zone 182 wherein the shape and rifling72 of the conical section 62 are continued, a recompression zone 184wherein the material after leaving the rifled sections is recompressed,and a shaping zone 186 wherein the waxed corrugated cardboard segmentmaterial is finally shaped such that the material exiting the log die 20is of the desired diameter and shape for the artificial firelog beingproduced.

[0124] As it has been found desirable to control the temperature of thelog die 20 during the formation of artificial firelogs 90, the log die20 is configured with a cooling jacket 82 surrounding the inner walls ofthe log die. The cooling jacket 82 allows the temperature of the log dieto be controlled by varying the amount and temperature of incomingcoolant which is routed into input 88 through the cooling jacket 82. Thecoolant exits the cooling jacket 82 by way of the outlet 92. Alternatelythe log die could be cooled with conventional means such as fans,cooling fins or similar heat dissipation structures. In addition it maybe desirable to cool the conveyor housing 26. The conveyor housing maybe cooled with conventionally known methods, such as a combination ofcooling fins and fans. A cooling jacket (not shown), may also be addedto the conical auger housing section 62 in similar manner to the coolingjacket 82 of the log die 20.

[0125]FIG. 50 is a schematic of the alignment of waxed corrugatedcardboard segments 48 around the periphery of the conveyor compressionscrew upon shaft 42. A clearance of approximately ¼″ exists between theouter circumferential edges of the helical blade and the circularpassageway 64, as seen in FIG. 50, the clearance allows interlocking ofthe compressed circumferentially-disposed waxed corrugated cardboardsegments 48 a near the inner surfaces of conical section 62 and log die20. Because waxed corrugated cardboard segments 48 are compressedcircumferentially around firelog 90, they open or expand (because ofmemory) with heat when burned, and the corrugations channel oxygenthroughout the segments within a firelog 90. Waxed corrugated cardboardsegments are more tightly twisted in the center of firelog 90,increasing their burn time. These radially disposed segments within thefirelog 90, provide for easy ignition and a high burn efficiency, whilethe resulting flames appear similar to the burning of a genuine barkfirelog.

[0126]FIG. 51 is a schematic of a firelog cross-section showingorientation of a few of the waxed corrugated cardboard segments 48 bradially disposed within the firelog.

[0127]FIG. 52 through FIG. 54 depict two log dies alternately beingconnected with the conical auger housing 26 (for clarity no fastenersare shown). FIG. 52 is a log die 20 for producing 4 inch artificialfirelogs. FIG. 53 is a log die 20 for producing 3½ inch artificialfirelogs. FIG. 54 is an end-view of the combined log die and augerhousing 26. It can be noted in these figures that the two sections matetogether with smooth transitions from within the conical section 62 ofthe auger housing 26 to the conical zone 182 of the log die 20, thistransition includes proper alignment of the rifling 72. Although logscan be produced without the alignment and smooth transitions, they allowthe extrusion of logs under reduced pressures.

[0128]FIG. 55 and FIG. 56 are a side and end view of an alternate logdie design 190. This log die schematic is shown with two separatinghalves 192, 194 which are bolted together and attached to the conicalauger housing (not shown). Additionally die-spacers 196, 198 are shown.By varying the width of the die-spacers 196, 198, firelogs may beextruded with variously sized longitudinal rails. The die-spacers canalternately be made to extend into the log extrusion area such that logsare produced with longitudinal grooves.

[0129]FIG. 57 is a side view of the cutting assembly for the waxedcorrugated cardboard. A plurality of lower circular blades 98 with teeth120, and a plurality of upper circular blades 100 with teeth performslicing of the waxed corrugated cardboard into strips and a cutting reel102 in conjunction with a bed bar knife 144 then cuts the strips intowaxed corrugated cardboard segments. Lower circular blades 98 arejuxtaposed along a lower axis 104 and are separated by spacers 106 whichmaintain a constant distance between each lower circular blade 98. Thespacers 106 are made with a recessed center to minimize the contact withthe irregular surface of the inner portion of the cutting blades. Uppercircular blades 100 are juxtaposed along an upper axis 108 and areseparated by spacers 110. Waxed corrugated cardboard sheets are fedalong channel 132 between a lower guide plate 128 and an upper guideplate 130. The cardboard material is cut into strips by the cuttingedges 116, 118. Avertical guide plate 140 prevents material strips thatexit the cutting blades from becoming re-engaged with the cuttingblades.

[0130] Waxed corrugated cardboard strips then arrive at shearing contactbetween cutting reel 102 that contains cutting blades 164 which shearthe cardboard against a cutting surface 142 of a bed bar knife retainedon a bed plate 146.

[0131]FIG. 58 shows one of the cutting blades 164 of the cutting reel102 as depicted in FIG. 57. The cutting blade is a generally rectangularmember containing a steel-edged longitudinal cutting surface which isused in combination with the bed bar knife (not shown) to shear thewaxed corrugated cardboard strips into cardboard segments.

[0132]FIG. 59 is the cutting reel 102 (non-mower type) as shown in FIG.57. The cutting reel retains a plurality of cutting blades 164 about acentral axis 162. The cutting blades 164 are shown helically attached tothe cutting reel 102 annularly disposed about the axis 162 in connectionwith a first and a second end panel 158, 160. Three inner support panels(not shown) are spaced evenly between first and second end panels 158,160 to retain the blades at a fixed radial distance from the centralaxis 162. Cutting blades 164 are positioned circumferentially betweenfirst and second end panels 158, 160 starting and ending with an angleof generally less than or equal to angle θ shown. Cutting blades 164 aregenerally retained parallel to the axial shaft 162 whereby rotation ofaxial shaft 162 thereby causes rotation of attached cutting blades 164.Typically the cutting reel 102 should have a diameter of at leastapproximately 8-inches, and the axial shaft 162 typically should have adiameter of at least approximately 1½ inches. Axial shaft 162 istypically 49-inches in length, with 2-inch threads, a 6-inch standardkey. The cutting reel may be fabricated from mild steel, case hardenedsteel or like material. Cutting reel 102 herein uses cutting blades 164wherein 8 such blades are preferred. The cutting blades 164 are equallyspaced apart, each having a length of approximately 36-inches. First andsecond end panels 158, 160 and the three inner support panels have slots(not shown) to provide access for cutting blades 164 to belongitudinally inserted therethrough at their proper angles. The angle θof the helical mounting of the blades is important, as too great anangle causes the chips to jam to one side of the machine. The angle θused within this embodiment is 12.5 degrees, as larger angles begancausing waxed corrugated strips to be pushed to one side making a wadthat the cutting reel jams on. To facilitate cutting and aid in themigration of waxed corrugated cardboard segments, the cutting blades 164are helically configured within the cutting reel 102. In this preferredconfiguration the cutting blades 164 have a left hand helix whilecutting reel 102 rotates counterclockwise.

[0133] Referring to FIG. 60, the mechanism which cuts the waxedcorrugated cardboard into strips is shown with a series of uppercircular blades 100 juxtaposed along an upper axis 108, comprising ashaft 114, wherein each of the upper circular blades are separated byspacers 110. Lower axis 104 comprises a lower shaft 112 upon which aseries of lower circular blades 98 separated by spacers 106 arejuxtaposed along a lower axis 104. Both lower shaft 112 and upper shaft114 are parallel and spaced apart such that the cutting edges 116 oflower circular blades 98 partially overlap the cutting edges 118 ofupper circular blades 100. Lower and upper shafts 112, 114, are of adiameter to fit into a correspondingly sized bore within lower and uppercircular blades 98, 100. A range of 40 to 50 blades are typically usedper axis. Upper shaft 114 used herein is approximately 50⅛ inches inlength and contains a full length standard keyway (not shown) with a2-inch threads portion starting from its left end. A collar (not shown)welded thereon allows for axially adjusting upper shaft 114 to allow forsome compression between lower and upper circular blades 98, 100. Lowershaft 112 used within this embodiment is approximately 56 inches longand includes a full length standard keyway (not shown) and 2-inches ofthreads at each end. Lower and upper shafts 112, 114 are fabricated frommild steel, case hardened steel or like material. Lower and uppercircular blades 98, 100 within this embodiment can range betweenapproximately 7¼ inches to 12-inches in diameter, but preferably, 8-inchnon-fluted hollow ground blades are should be used, because theircutting edges 116, 118 have non-fluted (straight) teeth 120 which arenecessary for grabbing and metered pulling of the material into themachine evenly for slicing and then pushing the waxed corrugatedcardboard strips to the cutting reel without slipping. The large numberof cutting teeth, although non-fluted, create uneven cutting tracks toprovide a fuzzy edge on the waxed corrugated cardboard being cut. Slicesof waxed corrugated cardboard sheets 122, or waxed corrugated cardboardboxes, are imparted with a fuzzy edge which operates to decrease thetime required to ignite a segment. FIG. 61 and FIG. 62 are side andfacing views of the spacer 106 used between the lower cutting blades;the spacers 110 used between the upper blades within this embodiment areinterchangeable with the spacers 106 for the lower cutting blades. Theannular face 200 of the spacer 106 is the only portion of the spacervisible exterior of the assembled apparatus. Spacers are mounted to ashaft via mounting hole 202 and retained by a shaft key engagement ofthe keyway 204.

[0134]FIG. 63 depicts the interaction of the upper and lower circularblades within the embodiment. Using an 8-inch circular blade, the depthof the overlap 138 between the cutting edges 116, 118 should be at least¼-inch. Teeth 120 are angled in such a manner to draw or pull one ormore waxed corrugated cardboard sheets into the cutting edges 116, 118,while not allowing the sheets to slip. During cutting, the teeth of thecutting blades impart a fuzzy edge to the waxed corrugated cardboardbeing cut. Circular blades 98, 100 within the embodiment are casehardened to a Rockwell hardness of 45 or greater, and are thick enough(approximately 0.080 inches) so as not to flex apart. Lower and upperspacers 106, 110 have a diameter of approximately 4½ inches to 5-incheswhen used with an 8-inch cutting blade since a minimum separation of 2½inches must be maintained between cutting edges 116 of lower circularblade 98 and lower spacers 106 and also between cutting edges 118 ofupper circular blades 118 and upper spacers 110. The included angle a ismeasured between the tips of the fully overlapping blades 98, 100 attips 116, 118 through the point 128 wherein the blade tips coincide. Theembodiment of the apparatus is configured with angle α set to 14.4degrees to ensure proper and reliable feeding of waxed corrugatedcardboard sheets, or boxes, 122 into cutting assembly.

[0135]FIG. 64 is a plan view of the lower guide plate 128 with aplurality of slots 126. The upper guide plate 130 (not shown) issimilarly slotted. The slots within the lower and upper guides plates128, 130 allow the cutting edges 116 of lower circular blades 98, andcutting edges 118 of upper circular blades 110 to extend therethroughfor engagement and cutting of the waxed corrugated cardboard material.Slots 126 are typically no greater than ¼ inches wide to help preventlower and upper circular blades 98, 100 from clogging. Lower and uppercircular blades are self-clearing due to their minimal clearances withinslots 126 in upper and lower guides plates 128, 130, as the slots 126extend only approximately 0.010 inches beyond the interposing circularblades.

[0136]FIG. 65 is a side view of the waxed corrugated cardboard cuttingassembly 12 showing waxed corrugated cardboard sheets 122 being fed intothe input side wherein the material is sliced into waxed corrugatedcardboard strips 134 and then segmented into waxed corrugated cardboardsegments 148. Lower and upper guide plates 128, 130 reside as generallyplanar sections between the lower and upper circular-blades 98, 100, andare typically parallel to each other near the junction of the upper andlower cutting surfaces. These two guide plates form a defined path, orchannel, 132 through which waxed corrugated cardboard sheets 122 canenter cutting assembly 12 and through which sliced waxed corrugatedcardboard strips 134 pass on their way to being segmented. The distancebetween the upper and lower guide plates 130, 128, respectively, providea channel 132 that helps direct the waxed corrugated cardboard sheets122 into the cutting blades.

[0137] A vertical guide plate 140 extends upwardly from upper guideplate 130 proximate to cutting reel 102 for separating waxed corrugatedcardboard strips 134 just prior to contact with cutting reel 102 whichprevent reverse flow of material. Lower guide plate 128 terminates atthe inner edge directly above the cutting surface 142 of a bed bar knife144. A bed plate 146 disposed below bed bar knife 144 directs waxedcorrugated cardboard segments 48 a towards, as shown in FIG. 1 throughFIG. 3, an opening 34 which is in material communication with conveyorcompression auger assembly 16. Attachment means 148, such as a nut andbolt, are used to attach bed bar knife 144 onto bed plate 146. The bedplate attaches by two outer studs which are threaded into each end ofthe bed plate and are fitted through the outer wall of the cuttingassembly. The bed plates are not fixed but swivel freely to allowadjustment; however they remain ridged in their horizontal anglerelationship to the reel. The pitch angle of bed plate 146 can beconfigured to provide for adjustment of the angle and to partiallycompensate for wear of the bed bar knife. As cutting blades 164 revolve,each blade passes in close proximity to cutting surface 142 of bed barknife 144, which results in shearing of the waxed corrugated cardboardstrips 134 passing therethrough into waxed corrugated cardboard segments48. Paper sheet layers may be added to the waxed corrugated cardboardsheets 122 so that a paper mix 60 is created with the waxed corrugatedcardboard segments 48 a. This paper mix is typically used forfirestarter material.

[0138]FIG. 66 is a schematic of the cutting reel 102 position inrelation to the cutting edge 142 of the bed bard knife 144. The axis ofrotation of the cutting reel within the embodiment is verticallydisposed by an angle λ, which for the embodiment is approximately 15degrees from the cutting edge 142 of the bed bar knife 144 when taken inrelation to direction of the lower guide plate 128.

[0139] Referring to FIG. 67 and FIG. 68, the left side and right side,respectively, of apparatus 10 is generally shown. A motor (not shown),or like means, provides the power necessary to operate apparatus 10.Those skilled in the art will appreciate that the motor can beelectrically powered, an internal combustion engine and/or be remotelylocated and coupled to apparatus 10 through a gear box (not shown). Ithas been determined, however, that for the embodiment thusly described,the motor must provide an output of at least 40 horsepower in order toproduce firelogs 90 while operating all the various subassembliessimultaneously.

[0140] In the preferred configuration (FIG. 67 and FIG. 68), the motor(not shown), powered by a frequency drive for speed control, directlydrives an 18-inch primary spur gear 166 that is axially mounted on aprimary driveshaft 168 which rotates within enclosure 14. Primary spurgear 166 in turn engages and drives a cutting assembly gear 170, whichis a 16-inch spur gear. Cutting assembly gear 170 is axially mounted onlower shaft 112 of the cutting assembly adjacent the left side 172 ofenclosure 14. Rotation of cutting assembly gear 170 rotates lower shaft112 and hence, lower circular blades 98. In FIG. 68, a lower shaft spurgear 174 is axially mounted on lower shaft 112 adjacent the right side178 of enclosure 14. The relationships of these gears can also be seenin FIG. 1 through FIG. 3, along with first gear housing 150 and secondgear housing 188 which enhance safety. Primary spur gear 166 anddriveshaft 168 are directly behind gear 56 and shaft 42 and can not beseen in FIG. 1 or FIG. 2, yet are in full view in the rear view of FIG.3. Lower shaft spur gear 174 engages and drives upper shaft spur gear176, which is attached to upper shaft 114 adjacent the right side 178 ofenclosure 14. Rotation of upper shaft spur gear 176 rotates upper shaft114 and hence, rotates upper circular blades 100. Lower shaft spur gear174 and upper shaft spur gear 176 are identically configured so that therotational velocities of lower and upper circular blades 98, 100 are thesame. In the preferred embodiment, lower shaft and upper shaft spurgears 174, 176, respectively, are approximately 8-inches in diameter.

[0141] Referring again to FIG. 67 the cutting reel 102 is driven by spurgear 170, which is driven by primary spur gear 166. Axial shaft 162 ofcutting reel 102 includes a gear 180 adjacent the left side 172 which isdriven by spur gear 170, which engages primary spur gear 166. In thepreferred configuration, gear 180 of cutting reel 102 is a spur gearthat is configured to provide a rotational velocity of approximately 4:1between lower circular blades 98 and cutting reel 102. The 4:1 ratiobetween lower circular blades 98 and cutting reel 102 is somewhatcritical as it determines the length and size of waxed corrugatedcardboard segments 48. The higher the ratio, the smaller the waxedsegments 48, and conversely, the lower the ratio, the larger the waxedsegments 48.

[0142] Primary spur gear 166 also drives shaft 42 of conveyorcompression auger screw 28. Primary spur gear 166 engages conveyorcompression auger screw spur gear 56, which is mounted on shaft 42.Conveyor compression auger screw spur gear 56, preferably, is alsoapproximately 18-inches in diameter to allow for the same rotationalvelocity in conveyor compression auger screw 28. Although gearingmechanisms are disclosed to drive cutting assembly 12 and conveyorcompression auger assembly 16, those skilled in the art will appreciatethat chain and sprocket assemblies (not shown), belt and pulleyassemblies (not shown) and/or a combination of any of the aforementionedcan be used to achieve the same objective.

[0143] To fabricate artificial firelog 90, flattened waxed corrugatedcardboard boxes in the form of waxed corrugated cardboard sheets 122, asshown in FIG. 65, are fed into channel or opening 132 until grasped bylower and upper circular blades with teeth 98, 100. Lower and uppercircular blades 98, 100 draw or pull waxed corrugated cardboard sheets122 into and meter through channel 132 while slicing waxed corrugatedcardboard sheets 122 into strips 134 while simultaneously applying fuzzyfrayed edges to the strips. As waxed corrugated cardboard strips 134pass through and exit channel 132, cutting blades 164 on cutting reel102 chop waxed corrugated cardboard strips 134 into waxed corrugatedcardboard segments 48. Referring now to FIG. 4, the waxed corrugatedcardboard segments fall from the cutting reel into hopper 18 and areguided into opening 34 of conveyor compression auger assembly 16. Thecardboard segments are then radially disposed to the inner walls of theconical section 62 where the ¼ riffling 72 guides the compressedsegments 48 b continually forward and through the conical zone 182 ofthe log die 20. The rifling 72 also insures that the outer layer of thelog will have a consistent layer of flattened radially disposedsegments. These segments are compressed through each flight of thecompression auger. As the segments reach the final compression (push)flight they have been arranged flat, horizontally, longitudinallydisposed, and helically compressed from the center of the log outward.The log die puts the last compression into the log extrusion and formsthe received compressed segments into various firelog products. Afirelog 90, as manufactured by the embodied apparatus, is shown in FIG.69 with a few representative waxed corrugated cardboard segments showndisposed radially on the surface of the log. For clarity, only a fewsegments are shown, however the log is comprised principally of thesewaxed corrugated cardboard segments 48. The firelog 90 shownadditionally contains a rail 96 which was formed by using a log diecontaining a longitudinal channel, or groove, such as the one describedin regard to the alternate log die of FIG. 55 and FIG. 56. Rails 96within the embodied log are approximately ⅛ to ¼ inches in width andextend approximately ⅛ to ¼ inches above the surface of firelog 90.Rails 96 ail function similarly to a candle-wick, and facilitatelighting of the firelog 90. The rails 96 also keep any log over-wrappingmaterial from sticking onto the surface of the firelog 90, whereby anair-gap is maintained to promote ignition of the firelog.

[0144] Referring to FIG. 70, the waxed corrugated cardboard segments 48a produced by the cutting assembly of the preferred embodiment areapproximately ½ to 1 square inch in size with frayed edges on each oftwo opposing sides created by the teeth on the pair of cutting bladeswithin the mechanism which performs the slicing operation. The waxcoating and corrugations of the original waxed corrugated cardboardsheets remain intact within these waxed corrugated cardboard segments.

[0145] Foreign metallic substances, such as staples, commonly found withwaxed corrugated cardboard sheets may be easily removed by usingmagnets, if this is desired, however the apparatus will operate withoutremoving the staples. FIG. 67 shows the hopper walls 152 whereupon whoseexterior magnetic means may be applied to prevent such metallicsubstances from entering the conveyor compression auger.

[0146] Waxed corrugated cardboard segments may also be directed from thecutting apparatus to a drying apparatus and then returned to the hopperbefore entering the conveyor compression auger.

[0147] To fabricate firestarter chips, a mix of paper and waxedcorrugated cardboard segments are produced by using cutting mechanismwithin the inventive apparatus. Referring to FIG. 65, paper sheets 124,preferably with 10% to 25% paper, are laid over waxed corrugatedcardboard sheets 122 and both are fed into opening 132 until grasped bylower and upper circular blades 98, 100. Lower and upper circular blades98, 100 slice waxed corrugated cardboard sheets 122 and paper sheets 124into waxed corrugated cardboard strips 134 and paper strips 136,respectively. Cutting blades 164 on cutting reel 102, chop waxedcorrugated cardboard strips 134 and paper strips 136 into waxedcorrugated cardboard segments 48 a and paper mix 60, respectively. Waxedcorrugated cardboard segments 48 a and paper mix 60 are gathered ordirected into to a standard bagging machine (not shown) for packagingthe waxed corrugated cardboard segments 48 a and paper mix 60 as anaggregate firestarter mix composed of approximately 80% waxed corrugatedcardboard segments 48 a and approximately 10% to 25% paper mix 60. Thoseskilled in the art will appreciate that approximately 20% of waxedcorrugated cardboard segments 48 a can be hammer-milled into acotton-like fiber which can be used in lieu of paper mix 60. Thiscotton-like fiber promotes rapid ignition when in an uncompressed state,such as the firestarter mix, however when the hammer-milled material iscompressed, the opposite effect occurs and rapid ignition is prevented.

[0148] Firelogs may be produced by leaving off the above described papersheets and further processing the waxed corrugated cardboard segments,that have been heretofore cut into segments. Referring to FIG. 4, afterthe uncompressed waxed corrugated cardboard segments 48 a are cut, theyfall into the hopper 18 and enter opening 34, the rotation of conveyorcompression screw 28 transports waxed corrugated cardboard segments 48 ainto and through auger housing 26. Conveyor compression screw 28 rotatesand compresses waxed corrugated cardboard segments 48 a along the lengthof the circular passageway 64, into compressed waxed corrugatedcardboard segments 48 b. As the waxed corrugated cardboard segments 48 bbeing compressed approach the recompression zone 184 of the log die 20,the segments 48 b are heated up due to the compression friction andcentrifugal force occurring therein. This heating propagates uniformlyand thereby adheres waxed corrugated cardboard segments 48 b together ina generally interlocking planar fashion. This interlocking planaradhesion of segments 48 b gives finished firelog 90 additional cohesivestrength with no cold joints. The conveyor compression auger assembly16, is operated (with regard to speed, cooling flow, and adjustment) soas to maintain the temperature of compressed waxed corrugated cardboardsegments 48 b under 150° F. At temperatures above 150° F. the “wet glue”used to form the waxed cardboard corrugations can melt resulting incorrugation delamination. Also, the wax used on the waxed cardboardsegments 48 a has a blocking point temperature of approximately 110° F.and a melting point temperature of approximately 142° F. The heatnecessary to form firelog 90, without melting the wet glue and wax inthe corrugated cardboard, is generated only by conveyor compressionscrew 28 and is typically about 50° F. to 55° F. above ambienttemperature. Firelogs 90 have been found to generally form best betweentemperatures of approximately 108° F. and 148° F., thus requiring anambient temperature range of approximately 53° F. to 93° F., which iswell within the range of most factories or manufacturing facilities. Ithas been determined that when the ambient temperature is lower, conveyorcompression auger assembly 16 can be run faster and consequently, morefirelogs 90 can be produced. Therefore, the ability to vary the ambienttemperature of the manufacturing environment is desirable. A coolingsection, as previously described and shown may be applied around the logdie to increase the production capability by further cooling andcontrolling the temperature.

[0149] Maintaining the integrity of the cellular structure 214, as shownin FIG. 71, is essential for allowing oxygen and wax to flow through thewaxed segments to provide for easier ignition and more efficient burningof the firelog 90 of FIG. 69. The centrifugal force within the conveyercompression auger assembly urges segments radially outward to theperiphery of firelog 90 so as to lay “flat” along the outer surface ofthe conical auger housing wherein upon compression these segments becomeradially disposed within firelog 90. Being radially disposed, the waxedcorrugated cardboard segments are free to expand when heated, therebyproviding a log which burns more efficiently and in a manner resemblinggenuine wood bark. Waxed corrugated cardboard segments are compressedwithin the apparatus by a factor of approximately five to eight. Theamount of compression, as set by the conveyor compression augerassembly, is a determiner of fuel density and a factor in regulating theburn rate of the log.

[0150] Additional wax or glue is not required within a firelog formedwithin the current invention, due to the unique configuration of theconveyor compression auger assembly, whose functioning includescompressing, radially disposing, and interlocking the waxed corrugatedcardboard segments into a firelog extrusion that does not easily breakapart. If desired, however, openings (not shown) can be placed withinconical section of the conveyor compression auger assembly so that extraliquid wax can be added to waxed corrugated cardboard segments. Thisextra wax can be used to achieve longer burn time, greater BTU's, or toreduce friction within the production process. The addition of wax, or awax replacement substance, may also be used with non-waxed corrugatedcardboard sheets or paper if used. As the firelog 90 burns, corrugations210 of the cellular structure 214 on the waxed corrugated cardboardsegments 48 b expand to 48 c (FIG. 73), allowing oxygen and wax topermeate throughout firelog 90, resulting in a clean and efficientburning firelog 90. The outermost segments of firelog 90 fall off andthe next outermost layer continues burning.

[0151] An outer coating or cover (not shown) can be extruded along withfirelog 90 by adding bleed holes on conical section 62 to allow for theintroduction of plastic or hot glues into the conveyor compression toform the outer coating or cover for firelog 90 during compression andextrusion. A means can also be provided wherein the plastic or hot glueis inserted beyond exit 76 of die 20. The outer coating or cover givesthe log structure a significantly greater compressive strength, therebyallowing the production of a log product extrusion whose outer coatingmay be made sufficiently durable so that the extrusion can be used forposts, pillars or the like.

[0152] Referring now to FIG. 69 through FIG. 73, a firelog 90 of FIG.69, manufactured by apparatus 10 of the present invention is generallyshown. As will be seen, firelog 90 is a longitudinally-shaped structurethat comprises waxed corrugated cardboard segments 48 b which have beenradially disposed and densely compacted together. The basic materialused to form firelog 90 is waxed corrugated cardboard sheets as foundwithin ordinary waxed corrugated cardboard boxes. The waxed corrugatedcardboard sheet(s) are cut into small segments 48 a of FIG. 70. Thewaxed corrugated cardboard segments are preferably cut to a size between½ square inch to 1 square inch in size to produce a decorative burnaspect of firelog 90. Alternatively, one can use waxed corrugatedcardboard segments 48 a smaller that the preferred range, but this wouldresult in a higher manufacturing cost and the possible introduction ofcold joints.

[0153] It is essential the waxed corrugated cardboard segments 48 aused, retain a cellular structure 214. The cellular structure mustremain intact in the form of corrugations 210 of cardboard material,which allow air to flow through the waxed corrugated cardboard segment48 a, which thereby results in an efficient and prolonged burn. Thewaxed corrugated cardboard segments 48 a additionally have been found toburn in a manner wherein they may be used as firestarter chips. Sincewaxed corrugated cardboard segments 48 a are fabricated from waxedcorrugated cardboard sheets, they contain a first substantially planarmember 212 and a second substantially planar member 216 coveringcorrugations 210 containing a cellular structure 214.

[0154] Waxed corrugated cardboard segments 48 a are compressed to aratio preferably between 5:1 and 8:1, resulting in a compressed waxedcorrugated cardboard segment 48 b as depicted in FIG. 72. The rangebetween 5:1 and 8:1 has been determined to be the preferred compressionratio as compressing waxed corrugated cardboard segment 48 beyond thisrange would cause damage to the cellular structure 214, thus effectivelyeliminating the effect of corrugations 210. After being compressed inthe conveyor compression auger assembly, waxed corrugated cardboardsegments 48 b are densely packed together during an extrusion processthrough log die 20 and then cut in generally evenly-spaced sections toform firelogs such as firelog 90 having a generally cylindrical-shapedstructure. Biomass may be added in with waxed corrugated cardboardsegments 48 during the compression process, including but not limited tosaw dust, almond shells, walnut shells, peanut shells, olive pits,cherry pits, coal. The addition of such biomass provides firelog 90 withdesired aromatic characteristics when firelogs 90 are burned. Biomasscan also serve to increase or decrease the friction level withinconveyor compression auger assembly during compression of waxedcorrugated cardboard segments 48.

[0155]FIG. 72 depicts the compressed waxed corrugated cardboard segments48 b as firelog begins to burn. Corrugations 210 then expand due to theheat, allowing air to efficiently flow throughout the segments whichexpand to 48 c of FIG. 73 as they burn on the outside of the firelog.

[0156] Referring finally to FIG. 74, a flow chart 220 of themanufacturing process for a firelog is generally depicted. The firststep 222 involves cutting waxed corrugated cardboard sheet intosegments. The second step 224 involves compressing waxed corrugatedcardboard segments to a ratio between 5:1 and 8:1. In the third step226, waxed corrugated cardboard segments are extruded into a continuouslog structure. The fourth and final step 228 involves cutting thecontinuous log structure into individual firelogs.

[0157] Accordingly, it will be seen that this invention convertsstandard waxed corrugated cardboard sheets into artificial firelogs byslicing the waxed corrugated cardboard sheets into strips, cutting waxedcorrugated cardboard strips into waxed corrugated cardboard segments,and compressing waxed corrugated cardboard segments, while providing forradial disposition and interlocking of the segments, to form anartificial firelog. Although the description above contains manyspecificities, these should not be construed as limiting the scope ofthe invention but as merely providing illustrations of some of thepresently preferred embodiments of this invention. Thus the scope ofthis invention should be determined by the appended claims and theirlegal equivalents. TABLE 1 Flight a f h r s 1 48.4° 5.500 1.239 0.25000.2292 2 51.4° 7.299 1.442 0.2500 0.3021 3a 57.4° 7.776 1.797 0.25000.3229  b — — 1.873 — —  c — — 2.092 — —  d — — 2.227 — — 4 57.4° 9.0002.227 0.2500 0.3750 5 57.4° 4.489 2.227 0.2500 0.4167

[0158] TABLE 2 St No. Flt Degree s b p w y t g 1 1  0-15 0.2292 1.770.27 1.43 1.77 1.77 0.250 2 1 15-30 0.2292 1.80 0.48 1.42 1.80 1.800.250 3 1 30-45 0.2292 1.82 0.69 1.33 1.82 1.09 0.250 4 1 45-60 0.22921.85 0.95 1.23 1.85 0.98 0.250 5 1 60-75 0.2292 1.87 1.02 1.14 1.21 0.940.250 6 1 75-90 0.2292 1.90 1.10 1.09 1.11 0.86 0.250 7 1  90-105 0.22921.92 1.10 1.09 0.83 0.84 0.250 8 1 105-120 0.2292 1.95 1.10 1.09 0.840.75 0.250 9 1 120-135 0.2292 1.97 1.10 1.09 0.63 0.75 0.250 10  1135-150 0.2292 2.00 0.93 1.10 0.61 0.75 0.250 11  1 150-165 0.2292 2.020.67 1.10 0.54 0.75 0.250 12-24 1 165-360 0.2292 2.05-2.32 0.50 1.100.54 0.78 0.250 25-48 2  0-360 0.3021 2.34-3.18 0.50 1.10 0.52 0.670.125 49-63 3  0-225 0.3229 3.22-3.72 -s- -s- -s- -s- 0.00 64-73 3-4225-15  0.3229 3.72 -s- -s- -s- -s- 0.00 74-97 4-5 15—15 0.3750 3.72 -s--s- -s- -s- 0.00  98-107 5  15-165 0.4167 3.72 -s- -s- -s- -s- 0.00

[0159] TABLE 3 Degree β₁ β₂ β₃  0-15  88.2° 48.1° 51.4° 15-30 100.3° — —30-45 110.8° — — 45-60 117.7° — — 60-75 126.9° — — 75-90 131.2° — —

What is claimed is:
 1. An apparatus for cutting, segmenting, compressingand extruding waxed corrugated cardboard sheets into a firelog havingradially interlocking segments, comprising: (a) a housing having aninlet end and an outlet end; (b) a plurality of circular bladesconfigured to slice at least one waxed corrugated cardboard sheet placedgenerally into the inlet end of said housing into cardboard strips; (c)a cutting reel configured to cut the cardboard strips into cardboardsegments; (d) a compression conveyor auger having shaft carrying ahelical blade with a plurality of flights; and (e) a die, wherein saidauger is configured to convey said cardboard segments into said diewherein the segments are compressed into a firelog.
 2. An apparatus asrecited in claim 1, further comprising at least one blade spacerpositioned between adjacent circular blades.
 3. An apparatus as recitedin claim 2, wherein said blade spacers are configured with recessedcenters to minimize the contact with an irregular inner surface of saidcircular blades to maintain a desired clearance between said blades. 4.An apparatus as recited in claim 1, wherein said plurality of circularblades comprises: (a) a plurality of lower circular blades juxtaposedalong a first common axis, said plurality of lower circular blades eachincluding a first cutting edge; (b) a plurality of upper circular bladesjuxtaposed along a second common axis, said plurality of upper circularblades each including a second cutting edge; and (c) a circular bladeaxial adjustment mechanism wherein the axial position of at least oneaxis of said circular blades can be positioned in relation to the otheraxis of circular blades to thereby provide control of the juxtapositionforces between upper and lower circular blades.
 5. An apparatus asrecited in claim 4, wherein said first common axis and said secondcommon axis are along a first shaft and a second shaft, respectively,whereby rotation of said first shaft causes rotation of said lowercircular blades and rotation of said second shaft causes rotation ofsaid upper circular blades.
 6. An apparatus as recited in claim 5,further comprising means for rotating said first and second shafts. 7.An apparatus as recited in claim 6, wherein said rotating meanscomprises a spur gear.
 8. An apparatus as recited in claim 1, whereinsaid cutting blades are configured with teeth which are annularlydisposed on the perimeter of said cutting blades.
 9. An apparatus asrecited in claim 8, wherein said teeth are non-fluted.
 10. An apparatusas recited in claim 1, wherein said cutting blades are hollow ground.11. An apparatus as recited in claim 4, wherein said first cutting edgeoverlaps said second cutting edge, and wherein said cutting blades areconfigured so that interaction between said upper cutting blades andsaid lower cutting blades proximal the location of cutting edge overlapcauses corrugated cardboard being sliceably passed therethrough toexhibit cut edges containing significant fraying.
 12. An apparatus asrecited in claim 11, wherein said significant fraying is created by therotating interaction of two hollow ground, non-fluted cutting blades.13. An apparatus as recited in claim 8, wherein said first cutting edgeoverlaps said second cutting edge, and wherein said overlap of firstcutting edge and second cutting edge of said teeth provide a meteredinput feed of waxed corrugated cardboard as the teeth grip the waxedcorrugated cardboard and the movement of the cutting blades pulls thewaxed corrugated cardboard therethrough at a predetermined rateproportional to the rotational speed of the cutters.
 14. An apparatus asrecited in claim 1, further comprising at least one guide plate attachedto the housing, said guide plate having slots configured to allow agenerally arcuate portion of said circular blades to pass therethrough,wherein said guide plates direct, or guide, the insertion of waxedcorrugated cardboard into the proper feed direction for slicing.
 15. Anapparatus as recited in claim 1, wherein a vertical guide plate isattached to the housing rearward of said circular blades in relation tothe direction of cardboard feed, and wherein a lower portion of saidvertical guide is aligned proximal to an upper guide plate on a lowerend and extends upwardly to a height which provides for separation ofwaxed corrugated cardboard strips prior to contact with said cuttingreel and additionally prevents reverse flow of material back into saidcircular blades.
 16. An apparatus as recited in claim 1, wherein saidcutting reel is mounted at a fifteen degree angle above the feed path ofsaid waxed corrugated cardboard strips into said cutting reel.
 17. Anapparatus as recited in claim 1, further comprising a geared drivemechanism for rotating said cutting reel.
 18. An apparatus as recited inclaim 17, wherein said geared drive includes a set of spur gearsconnected to said cutting reel through which power is applied to rotatesaid cutting reel.
 19. An apparatus as recited in claim 1, wherein saidcutting reel comprises: (a) a first and a second end plate; (b) an axialshaft positioned perpendicularly between said first and said second endplate; and (c) a plurality of longitudinal cutting blades disposedaround said axial shaft, paddle-wheel style, which are retainedgenerally parallel to said axial shaft and attached to said first andsaid second end plate.
 20. An apparatus as recited in claim 19, whereinsaid cutting blades in said cutting reel include a helical twistextending between said first and said second end plate.
 21. An apparatusas recited in claim 19, wherein a bed bar knife is attached to saidhousing anterior of said circular blades in relation to the direction ofcardboard material feed, and wherein said bed bar knife is alignedproximal to lower guide plate positioned such that an edge of said bedbar knife is brought into material shearing proximity with saidlongitudinal cutting blades of said cutting reel so that the strips ofwaxed corrugated cardboard material passing rearwardly of said circularcutting blades are placed in shearing contact between the bed bar knifeand reel for the production of segments thereof.
 22. An apparatus asrecited in claim 21, wherein a bed plate is configured for retention ofsaid bed bar knife to allow interchangeable replacement of bed barknives, wherein said bed plate is attached to said housing and retainssaid bed bar knife using at least one fastener in a position whichprovides shearing of the waxed corrugated cardboard strips into waxedcorrugated cardboard segments.
 23. An apparatus as recited in claim 22,wherein said bed bar knife is retained by said bed plate withnon-adjustable fasteners.
 24. An apparatus as recited in claim 22,wherein said bed bar knife is retained by at least one fastener whichprovides longitudinal adjustment of the bed bar knife in relation to thebed plate.
 25. An apparatus as recited in claim 24, wherein saidfastener comprises a turnbuckle.
 26. An apparatus as recited in claim 1,further comprising a conveyor auger housing, said conveyor auger housingincluding rifling to aid the control of radial disposition andinterlocking alignment of the waxed cardboard segments as extruded intothe artificial firelog.
 27. An apparatus as recited in claim 1, whereinthe cardboard segments are compressed to a ratio between approximately5:1 and approximately 8:1.
 28. An apparatus as recited in claim 1,further comprising means for rotating said compression conveyor auger.29. An apparatus as recited in claim 28, wherein said rotating meanscomprises a spur gear.
 30. An apparatus as recited in claim 1, whereinsaid helical blade is tapered.
 31. An apparatus as recited in claim 1,wherein said flights of said helical blade decrease in length towardsaid housing.
 32. An apparatus as recited in claim 1, wherein the sideprofile of said helical blade becomes increasingly cupped towards saidoutlet end of said housing.
 33. An apparatus as recited in claim 1,wherein said helical blade is configured with a buildup of weld materialof a predetermined shape at the junction of said helical blade and saidauger shaft, wherein said buildup of weld material provides a finalpushing thrust of said segments into said die.
 34. An apparatus asrecited in claim 1, wherein said log die sets the cross-sectional shapeof an extruded firelog.
 35. An apparatus as recited in claim 34, whereinsaid log die includes a compression zone.
 36. An apparatus as recited inclaim 1, wherein said log die includes at least one longitudinal surfacegroove which produces logs with protruding ridges.
 37. An artificialfirelog manufacturing apparatus, comprising: (a) an enclosure; (b) meansfor converting waxed corrugated cardboard into waxed corrugatedcardboard segments, said converting means located within said enclosure;(c) a housing within said enclosure, said housing including an inlet endand an outlet end, wherein said outlet end is tapered; (d) an opening onsaid housing, said opening disposed adjacent said inlet end of saidhousing; and (e) a compression conveyor screw rotatably disposed withinsaid housing, said conveyor screw including a helical blade extendingbetween said inlet end and said outlet end of said housing, said helicalblade including a plurality of flights.
 38. An apparatus as recited inclaim 37, wherein the diameter of said helical blade tapers towards saidoutlet end of said housing.
 39. An apparatus as recited in claim 38,wherein said housing has a length greater than seventeen inches andwherein the tapering of said helical blade occurs approximately withinapproximately the final seventeen inches of the housing toward saidoutlet end.
 40. An apparatus as recited in claim 37, wherein saidflights have a length that diminishes toward said outlet end of saidhousing.
 41. An apparatus as recited in claim 37, wherein said helicalblade is cupped and canted forward toward said outlet end of the lasttwo flights.
 42. An apparatus as recited in claim 37, wherein theattachment area of the last helical flight of said helical blade withsaid shaft includes a fillet between said shaft and said helical bladewhich provides thrust, or final pushing, of said segments into thecompression die.
 43. An apparatus as recited in claim 42, wherein saidfillet is formed from weld material.
 44. An apparatus as recited inclaim 37, further comprising a hopper disposed within said enclosure,said hopper in communication with said opening of said housing and saidwaxed corrugated cardboard sheet converting means.
 45. An apparatus asrecited in claim 37, wherein said waxed corrugated cardboard convertingmeans comprises: (a) a plurality of lower circular blades juxtaposedalong a first common axis, said plurality of lower circular blades eachincluding a first cutting edge; (b) a plurality of upper circular bladesjuxtaposed along a second common axis, said plurality of upper circularblades each including a second cutting edge; (c) said plurality of lowerand upper circular blades configured to slice the waxed corrugatedcardboard placed therebetween into waxed corrugated cardboard strips,whereby said first common axis is parallel to said second common axis,and said first cutting edge overlaps said second cutting edge; and (d) acutting reel positioned to receive the waxed corrugated cardboardstrips, said cutting reel capable of chopping the waxed corrugatedcardboard strips into waxed corrugated cardboard segments.
 46. Anapparatus as recited in claim 45, wherein each of said cutting edges ofsaid lower circular blades and said upper circular blades comprises aplurality of teeth.
 47. An apparatus as recited in claim 46, whereinsaid teeth are non-fluted.
 48. An apparatus as recited in claim 45,wherein a plurality of blade spacers are interleaved between saidplurality of lower and upper circular blades such that the spacingbetween cutting blades, and thereby the width of the waxed corrugatedcardboard slices, is set by the thickness of the spacers used.
 49. Anapparatus as recited in claim 48, wherein said blade spacers areconfigured with recessed centers to minimize the contact with theirregular inner surface of the circular blades to maintain properclearances between blades.
 50. An apparatus as recited in claim 45,wherein an upper guide plate and lower guide plate are positioned inrelation to the upper and lower circular blades, respectively, andadjusted so as to direct waxed corrugated cardboard into said apparatusfor proper slicing by the combination of upper and lower circularblades.
 51. A firelog manufacturing apparatus, wherein waxed corrugatedcardboard sheets are segmented and compressed as radially interlockingsegments within a manufactured composite firelog extrusion, comprising:(a) a housing for the apparatus which includes an inlet end and anoutlet end; (b) a plurality of lower circular blades juxtaposed along afirst common axis, said plurality of lower circular blades eachincluding a first cutting edge; (c) a plurality of upper circular bladesjuxtaposed along a second common axis; said plurality of upper circularblades each including a second cutting edge; (d) said plurality of lowerand upper circular blades configured to slice at least one waxedcorrugated cardboard sheet placed therebetween and generally into theinput end of said housing, into cardboard strips, whereby said firstcommon axis is approximately parallel to said second common axis, andsaid first cutting edge overlaps said second cutting edge; (e) a cuttingreel positioned to receive the waxed corrugated cardboard strips, saidcutting reel capable of cutting the waxed corrugated cardboard stripsinto waxed corrugated cardboard segments; (f) a conveyor auger housingwhich includes an inlet end and an outlet end, wherein said outlet endis tapered, said conveyor auger housing is held in a fixed relation tosaid apparatus housing; (g) an opening on said conveyor auger housing,wherethrough waxed cardboard segments enter said conveyor auger housing;(h) a compression conveyor screw rotatably disposed within said conveyorauger housing, said compression conveyor screw including a helical bladeextending toward said outlet end of said conveyor auger housing, saidhelical blade including a plurality of flights; (i) a log extrusionorifice configured on the terminating end of said outlet end of saidconveyor auger housing, wherethrough composite material is extruded, asa result of the rotation of the compression conveyor screw, into apredetermined cross-sectional shape; and (j) means for segmenting thecomposite firelog extrusion into individual log sections.
 52. Anapparatus as recited in claim 51, wherein at least one blade spacerseparates and provides spacing between each of said plurality of lowerand upper circular blades.
 53. An apparatus as recited in claim 52,wherein said blade spacers are configured with recessed centers tominimize the contact with the irregular inner surface of the curricularblades to maintain proper clearances between blades.
 54. An apparatus asrecited in claim 51, further including a circular blade axial adjustmentwherein the axial position of at least one axis of said circular bladescan be positioned in relation to the other axis of circular blades tothereby provide control of the juxtaposition forces between upper andlower circular blades.
 55. An apparatus as recited in claim 51, whereinsaid first common axis and said second common axis comprise a firstshaft and a second shaft, respectively, whereupon rotation of said firstshaft causes rotation of said lower circular blades and rotation of saidsecond shaft causes rotation of said upper circular blades.
 56. Anapparatus as recited in claim 55, further comprising means for rotatingsaid first common axis and said second common axis.
 57. An apparatus asrecited in claim 56, wherein said rotating means comprises a spur gear.58. An apparatus as recited in claim 51, wherein said cutting blades areconfigured with teeth which are annularly disposed on the perimeter ofsaid cutting blades, wherein said teeth facilitate the rapid cutting ofthe waxed corrugated cardboard without slippage.
 59. An apparatus asrecited in claim 58, wherein said teeth disposed on perimeter of saidcutting blades are non-fluted.
 60. An apparatus as recited in claim 51,wherein said cutting blades are hollow ground.
 61. An apparatus asrecited in claim 51, wherein said cutting blades are configured so thatinteraction between said upper cutting blades and said lower cuttingblades proximal the location of cutting edge overlap causes corrugatedcardboard being sliceably passed therethrough to exhibit cut edgescontaining significant fraying.
 62. An apparatus as recited in claim 61,wherein said significant fraying is created by the rotating interactionof two hollow ground, non-fluted cutting blades.
 63. An apparatus asrecited in claim 51, wherein said overlap of first cutting edge andsecond cutting edge of said teeth provide a metered input feed of waxedcorrugated cardboard as the teeth grip the waxed corrugated cardboardand the movement of the cutting blades pulls the waxed corrugatedcardboard therethrough at a predetermined rate proportional to therotational speed of the cutters.
 64. An apparatus as recited in claim51, wherein at least one guide plate is attached to the housing, whereinsaid guide plates are configured with slots to allow a generally arcuateportion of said circular blades to pass therethrough, wherein said guideplates direct, or guide, the insertion of waxed corrugated cardboardinto the proper feed direction for slicing by the combination of upperand lower circular blades.
 65. An apparatus as recited in claim 51,wherein a vertical guide plate is attached to the housing anterior ofsaid circular blades, in relation to the direction of material feed, andwherein a lower portion of said vertical guide is aligned proximal toupper guide plate on a lower end and extends upwardly to a height whichprovides for separation of waxed corrugated cardboard strips prior tocontact with cutting reel and additionally prevents reverse flow ofmaterial back into said circular blades.
 66. An apparatus as recited inclaim 51, wherein said cutting reel is mounted at a fifteen degree angleabove the feed path of said waxed corrugated cardboard strips into saidcutting reel.
 67. An apparatus as recited in claim 51, furthercomprising a geared drive for rotating said cutting reel.
 68. Anapparatus as recited in claim 67, wherein said geared drive includes aset of spur gears connected to said cutting reel through which power isapplied to rotate said cutting reels.
 69. An apparatus as recited inclaim 51, wherein said cutting reel comprises: (a) a first and a secondend plate; (b) an axial shaft positioned perpendicularly between saidfirst and said second end plate; and (c) a plurality of longitudinalcutting blades disposed around said axial shaft, paddle-wheel style,which are retained generally parallel to said axial shaft and attachedto said first and said second end plate.
 70. An apparatus as recited inclaim 51, wherein said cutting blade of said cutting reel includes ahelical twist extending between said first and said second end plate.71. An apparatus as recited in claim 69, wherein a bed bar knife isattached to said apparatus housing anterior of said circular blades, inrelation to the direction of material feed, and said bed bar knife isaligned proximal to lower guide plate positioned such that an edge ofsaid bed bar knife is brought into material shearing proximity with saidlongitudinal cutting blades of said cutting reel so that the strips ofwaxed corrugated cardboard material passing rearwardly of said circularcutting blades are placed in shearing contact therebetween bed bar knifeand reel for the production of segments thereof.
 72. An apparatus asrecited in claim 71, wherein a bed plate is configured for retention ofsaid bed bar knife, to allow interchangeable replacement of bed barknives, wherein said bed plate is attached to said apparatus housing andtherein retains said bed bar knife by means of at least one fastener, ina position which provides shearing of the waxed corrugated cardboardstrips into waxed corrugated cardboard segments.
 73. An apparatus asrecited in claim 72, wherein said bed bar knife is retained by said bedplate with non-adjustable fasteners.
 74. An apparatus as recited inclaim 72, wherein said bed bar knife is retained by at least onefastener which provides longitudinal adjustment of the bed bar knife inrelation to the bed plate.
 75. An apparatus as recited in claim 74,wherein said fastener is a turnbuckle.
 76. An apparatus as recited inclaim 51, further including rifling within said conveyor auger housing,wherein said rifling aids the control of radial disposition andinterlocking alignment of the waxed cardboard segments as extruded intothe artificial firelog.
 77. An apparatus as recited in claim 51, whereinthe cardboard segments being transported through the conveyor augerhousing are compressed to a ratio between approximately 5:1 andapproximately 8:1.
 78. An apparatus as recited in claim 51, furthercomprising a means for rotating said compression conveyor screw.
 79. Anapparatus as recited in claim 78, wherein said conveyor screw rotatingmeans comprises a spur gear.
 80. An apparatus as recited in claim 51,wherein said helical blade includes a diameter that decreases towardssaid outlet end of said conveyor auger housing.
 81. An apparatus asrecited in claim 51, wherein said flights of said helical blade decreasein length toward said outlet end of said conveyor auger housing.
 82. Anapparatus as recited in claim 51, wherein the side profile of saidhelical blade becomes increasingly cupped towards said outlet end ofsaid conveyor auger housing.
 83. An apparatus as recited in claim 51,wherein said helical blade is configured with a buildup of weld materialof a predetermined shape at the junction of said helical blade and saidauger shaft, wherein said buildup of weld material provides a finalpushing thrust of said segments through outlet end of said conveyorauger housing.
 84. An apparatus as recited in claim 51, furtherincluding a log die attached to said log extrusion orifice, wherein saidlog die provides for modifying the cross-sectional shape of theextrusion.
 85. An apparatus as recited in claim 84, wherein said log diecomprises a compression zone proximal to the attachment of said auger.86. An apparatus as recited in claim 51, wherein said log die includesat least one longitudinal internal surface groove which produces logswith protruding ridges.
 87. A compression conveyor auger assembly, fortransporting and compressing waxed corrugated cardboard segments,comprising: (a) a housing, said housing including an inlet end and anoutlet end, wherein said outlet end is tapered; (b) an opening on saidhousing, said opening disposed adjacent said inlet end of said housing;and (c) a compression conveyor screw rotatably disposed within saidhousing, said compression conveyor screw including a helical bladeextending between said inlet end and said outlet end of said housing,said helical blade including a plurality of flights.
 88. An apparatus asrecited in claim 87, wherein the diameter of said helical bladedecreases towards said outlet end of said housing, and wherein saidflights decrease in length toward said outlet end of said housing. 89.An apparatus as recited in claim 88, further comprising a log dieattached to said outlet end of said housing.
 90. An apparatus as recitedin claim 89, wherein said log die includes at least one internallongitudinal groove therein.
 91. An apparatus as recited in claim 87,wherein said housing includes a circular passageway having rifling. 92.An apparatus as recited in claim 87, wherein the cardboard segmentsbeing transported therethrough are compressed to a ratio betweenapproximately 5:1 and approximately 8:1.
 93. An apparatus as recited inclaim 87, further comprising means for rotating said compressionconveyor screw.
 94. An apparatus as recited in claim 93, wherein saidconveyor screw rotating means comprises a spur gear.
 95. An apparatus asrecited in claim 87, further including means for segmenting thecomposite firelog extrusion into individual log sections.
 96. Anapparatus as recited in claim 87, wherein said helical blade includes adiameter that decreases towards said outlet end of said housing.
 97. Anapparatus as recited in claim 96, wherein said flights of said helicalblade decrease in length toward said outlet end of said housing.
 98. Awaxed corrugated cardboard cutting assembly, comprising: (a) a pluralityof lower circular blades juxtaposed along a first common axis, saidplurality of lower circular blades each including a first cutting edge;(b) a plurality of upper circular blades juxtaposed along a secondcommon axis, said plurality of upper circular blades each including asecond cutting edge; (c) said plurality of lower and upper circularblades configured to slice the at least one waxed corrugated cardboardsheet placed therebetween into cardboard strips, whereby said firstcommon axis is generally parallel to said second common axis, and saidfirst cutting edge overlaps said second cutting edge; and (d) a cuttingreel positioned to receive the waxed corrugated cardboard strips, saidcutting reel capable of cutting the waxed corrugated cardboard stripsinto waxed corrugated cardboard segments;
 99. An apparatus as recited inclaim 98, wherein said common axis of said circular blades is axiallyadjustable to provide control of the interface force between upper andlower circular blades.
 100. An apparatus as recited in claim 98, whereineach of said cutting edges of said lower circular blades and said uppercircular blades comprise a plurality of non-fluted teeth.
 101. Anapparatus as recited in claim 98, wherein said first common axis andsaid second common axis comprise a first shaft and a second shaft,respectively, whereupon rotation of said first shaft causes rotation ofsaid lower circular blades and rotation of said second shaft causesrotation of said upper circular blades.
 102. An apparatus as recited inclaim 101, further comprising means for rotating said first and saidsecond shafts.
 103. An apparatus as recited in claim 102, wherein saidfirst and said second shaft rotating means comprises spur gears.
 104. Anapparatus as recited in claim 98, further comprising means for rotatingsaid cutting reel.
 105. An apparatus as recited in claim 104, whereinsaid cutting reel rotating means comprises a spur gear.
 106. Anapparatus as recited in claim 98, further comprising: (a) a lower guideplate which includes a plurality of slots through which said firstcutting edges of said lower circular blades extend therethrough; and (b)an upper guide plate which includes a plurality of slots through whichsaid second cutting edges of said upper circular blades extendtherethrough, wherein said lower guide plate and said upper guide plateform a channel therebetween for receiving and aligning waxed corrugatedcardboard sheets for cutting by the circular blades.
 107. An apparatusas recited in claim 98, wherein a vertical guide plate is positionedanterior of said upper circular blades with a lower end aligned proximalto the upper guide plate with an upper end extending upwardly to aheight which provides for separation of waxed corrugated cardboardstrips prior to contact with cutting reel and prevents reverse flow ofmaterial back into said circular blades.
 108. An apparatus as recited inclaim 98, wherein a bed bar knife is positioned anterior of said lowercircular blades with a top portion aligned proximal to lower guide platewheresopositioned at least one edge of said bed bar knife is in materialshearing proximity with moveable portions of said reel such thatinterposing waxed corrugated cardboard material being fed into theapparatus is placed in shearing contact therebetween bed bar knife andreel and sheared into waxed corrugated cardboard segments.
 109. Anapparatus as recited in claim 98, wherein a bed plate is configured forattachment of said bed bar knife, and wherein said bed plate retainssaid bed bar knife in a position for material shearing therebetween saidcutting reel.
 110. An apparatus as recited in claim 109, wherein saidbed bar knife is retained by said bed plate with non-adjustablefasteners.
 111. An apparatus as recited in claim 109, wherein said bedbar knife is retained by at least one fastener which provideslongitudinal adjustment of the bed bar knife in relation to the bedplate.
 112. An apparatus as recited in claim 111, wherein said fastenercomprises a bolt with nut which flexibly retains bed bar knife to bedplate and a turnbuckle configured to provide an adjusting force whereinthe bed bar knife may be adjustably retained in the correct shearingposition in relation to the cutting reel.
 113. An apparatus as recitedin claim 98, wherein said cutting reel is mounted at an approximatefifteen degree angle above the direction in which the waxed corrugatedcardboard slices travel upon exiting anterior of said upper and lowercutting blades after being sliced.
 114. An apparatus as recited in claim98, wherein said cutting reel comprises: (a) a first and a second endplate; (b) an axial shaft positioned perpendicularly between said firstand said second end plate; and (c) a plurality of cutting bladesdisposed around said axial shaft, said cutting blades spaced equallyapart and generally parallel to said axial shaft; said cutting bladesattached to said first and said second end plate; wherein each saidcutting blade includes a helical twist extending between said first andsaid second end plate.
 115. An apparatus as recited in claim 114,wherein said helical twist of each said cutting blade does not exceed anangle generally over 13 degrees between said first and second endplates.
 116. An artificial firelog comprising a plurality of compressedsegments of waxed corrugated cardboard which are radially disposedwithin said firelog.
 117. An artificial firelog as recited in claim 116,wherein said compressed segments have been compressed to a thicknessbetween approximately ⅛th and approximately ⅕th of their originalthickness without generally having their corrugated structure destroyedor glued together.
 118. An artificial firelog as recited in claim 116,wherein said compressed segments of waxed compressed corrugatedcardboard have opposing frayed edges.
 119. An artificial firelog asrecited in claim 116, wherein during the burning of said firelog theheated waxed segments expand by memory to provide an artificial logwhich burns efficiently in a manner resembling continuous bark burningof a natural firelog as each segment is consumed and the next segmentsstarts burning.
 120. A firestarter chip manufactured using a cuttingassembly as recited in claim 98, comprising: (a) a first substantiallyplanar member; (b) a second substantially planar member; (c) acorrugated section disposed between said first substantially planarmember and said second substantially planar member; and (d) means foradhering said corrugated section to said first substantially planarmember and said second substantially planar member.
 121. An artificialfirelog manufactured by an apparatus as recited in claim 1, comprising aplurality of compressed segments of waxed corrugated cardboard which areradially disposed within said firelog.
 122. An artificial firelog asrecited in claim 121, wherein said compressed segments have beencompressed to a thickness between approximately ⅛th and approximately⅕th of their original thickness without generally having theircorrugated structure destroyed or glued together.
 123. An artificialfirelog as recited in claim 121, wherein said compressed segments ofwaxed compressed corrugated cardboard include opposing frayed edges.124. A firelog as recited in claim 121, wherein said firelog includes atleast one longitudinally-disposed rail thereon.
 125. A method formanufacturing firestarter chips using the cutting assembly recited inclaim 98, comprising the steps of: (a) slicing a waxed corrugatedcardboard sheet into cardboard strips; (b) slicing at least one sheet ofpaper into paper strips simultaneous to said slicing said waxedcorrugated cardboard sheet strips; and (c) chopping said cardboardstrips and said paper strips into waxed corrugated cardboard segmentsand paper segments, respectively.
 126. A method for manufacturingfirestarter chips as recited in claim 125, further comprising the stepsof: (a) gathering said waxed corrugated cardboard segments and saidpaper segments; and (b) packaging said waxed corrugated cardboardsegments and said paper segments.
 127. A method for manufacturing anartificial firelog using an apparatus recited in claim 37, comprisingthe steps of: (a) converting waxed corrugated cardboard sheets intosegments; (b) compressing said waxed corrugated cardboard segments to aratio approximately between 5:1 and 8:1; (c) extruding said compressedwaxed corrugated cardboard segments into a continuous log structure; and(d) cutting said continuous log structure into individual firelogs. 128.A method for manufacturing an artificial firelog as recited in claim127, further comprising the step of arranging waxed corrugated cardboardsegments flat horizontally disposed between the rifling in the housingand helical blade of the conveyor screw wherein so aligned saidcorrugated cardboard segments become radially disposed interlockingsegments within the artificial firelog extrusion.
 129. A method formanufacturing segments of waxed corrugated cardboard from waxedcorrugated cardboard sheets in accordance with the apparatus of claim98, comprising the steps of: (a) slicing said waxed corrugated cardboardsheets into waxed corrugated cardboard strips; and (b) chopping saidwaxed corrugated cardboard strips into waxed corrugated cardboardsegments.
 130. A method as recited in claim 129, wherein said step ofslicing said waxed corrugated cardboard sheets is performed so thatopposing frayed edges are created on said waxed corrugated cardboardstrips.